Stoked that this has worked for you as well. I have also put up a post on the Ranger PJ/PK Facebook page & waiting on peop0les feedback from there.. If I have a few guys confirming this works, then I will feel confidant that I have finally found a permanent fix for this bloody issue.

Can't tell you how frustrating this has been since It first appeared 18 mths ago. I have had to give up doing some 4x4 tracks on arrival because of this, absolutely maddening Ford dealerships were absolutely clueless & remain that way. They wanted to sell me 4x4 control modules for about $1,500 or new shift motors for about the same. Had nothing else to offer!

Who'd have thought it has turned out to be a 5 minute fix with a screwdriver that costs bugger all

If moving the plate a small amount restores the original function, it would indicate there is some crap on the internal contacts.
Maybe, removing the plate and cleaning the contacts and rotary plate fingers, then add some white lithium grease, may keep it all functional into the future and not give any more trouble.

Hey mydmax. It's a sealed unit so you can't get to the contacts. They don't get dirty cause it's sealed, the problem is that the position sensor moves over time. I believe that's why that plate has been made adjustable. An improvement over the old setup in the explorers.

fleetwood wrote:
For anybody that does still have the problem, try this.... Loosen (DO NOT REMOVE) the three screws on the shift motor position sensor plate ( see pics), then swivel that plate a little & retighten.

Hey Rob
That was going to be the next thing I tried! Has that solved it for you? Mine is so intermittent that it is hard to tell when I have done something that works, or if the problem has gone away on its own, only to come back again a couple of months later.

Hi drodda. Yeah mine has worked perfectly since doing this. Mine was intermittent as well. Usually when I really needed it most (Murphy's law haha ).

So now looking to spread the word so that people can try this next time the problem shows up. Feeling confident that if it's a position sensor fault, which it mostly seems to be, this will be a final fix.

Be bloody nice to have confidence restored that when you go to select 4WD, it's actually going to work!

Ok fleetwood, I might just also add 'you bloody legend' as I did this today and it appears to have fixed the issue !!
Haven't pick up that $50 console switch yet either, so that may well be staying with the dealer.

Found the screws over to one side of the slots, all screws were tight.
Got the T-15 bit and loosened off the 3 screws, turned to about the middle of the slot adjustment.
Tightened up screws (on the last one the tip of the T-15 snapped off, so watch that).

See pics below of where these settings were.

Ok, so I went down to a gravel carpark a few ks from home, and flipped from 2H to 4H while stationary in D.
Hmmm, same old thing, 4H came on, but then 4L came on too, even though in 4H !!
Was a bit worried then, but persevered to give it some more trials.

So, usual thing, switch to 2H and doesn't go out, so into P and turn off, leave a minute, and restart.
All normal again in 2H.
So I drive off in 2H, flick to 4H doing about 20k and goes into 4H no probs, and no follow on 4L, yay

Ok, test 4L, stopped in N, all good changes as it should.
Again stopped in N turned it back to 4H and there it goes, good as gold

Did this a few more times and all seems ok, expect it had to maybe settle in or reset or something ?

Will give it a darn good going tomorrow down in another paddock somewhere, see if it stays good.

Here are some pics or the adjustment done . . . before and after . . .
..

Before

1-4wdModuleB4.jpg

After

2-4wdModuleAFTER.jpg

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Hey Les... Glad it seems to have worked for you. I chuck mine into 4H on the fly about 3 or 4 times day now just to check. It's worked faultlessly ever since I did this to mine. Same with 4L. Bloody stoked

I you do still have problems, it may be some other cause. Have a look at doing the diagnostic & checking for stored codes as I explained a few pages back. If it's the shift motor position sensor, (3 long flashes), then I'm almost 100% confident this fix will sort it for good.

Mine's still giving probs, but less frequently now.
Should have replacement T15 today ,so will adjust back a bit and try, if still not perfect will go a little past half way and see.
I have a horrible feeling it might be module, but won't give up hope just yet